:.

By Eng Ahmad Nader

Manager of the Specialized maintenance

 Shell Deformation Causes

Radial
deformation
and it’s
Effect
 Shell
Deformation
measuremen
ts using
Manual
method
Kiln Shell
Run out
record
 KILN SHELL RUNOUT TEST ECORD
Test Dimensions 189o
Signs Reversed For
Above OR Blow Average
mm RUNOUT Plotting

1 120.65 7 174.635 53.975 1 -26.187 7 + 27.788 1 + 26.187 7 - 27.788

2 130.175 8 184.15 53.975 2 -16.662 8 + 37.313 2 + 16.662 8 - 37.313

3 133.35 9 165.1 31.75 3 -13.487 9 + 18.263 3 + 13.487 9 - 18.263

4 146.05 10 133.35 12.70 4 -0.787 10 -13.487 4 + 0.787 10 - 13.487

5 168.275 11 123.825 44.45 5 + 21.438 11 -23.012 5 - 21.438 11 + 23.012

6 168.275 12 114.3 53.975 6 + 21.438 12 -32.537 6 - 21.438 12 + 32.537

TOTAL = 1762.125 TOTAL RUNOUT = - 37.313 " TO + 32.537 " = 69.850 "

DATE TESTED:24/04/2005 VERIFIED BY : Eng/A.Nader

AVERAGE = 146.837
Kiln Shell Run out Profile
Crank in Kiln Shell

Mechanical crank

Thermal crank
 Mechanical crank

Mechanical crank is a stationary deformation of the kiln shell

axis. It exists in the kiln whether hot or cold and cannot be
affected by conditions of operation.

A mechanical crank may occur if an unsuitable procedure

has been chosen in connection with straightening and
welding together of the individual kiln sections, or if the work
is not done with sufficient care.
 Thermal crank

Thermal crank results from an uneven kiln surface

temperature distribution. It exists in the hot kiln only and
can be affected by conditions of operation.

Areas of the shell showing larger temperature variations in

the perimeter directions are unfailing signs of the existence
of a thermal crank. Generatrices in the hot areas become
longer than generatrices in the colder areas resulting in
warpage of the kiln.
 Elimination or repair of cranks

Re-conditioning of a kiln with a crank is usually a

complicated and costly task. This is primarily due to the fact
that the repair as a rule means a shutdown of the kiln for a
long period of a time. A number of cuts of the kiln are
required as well as straightening, welding together of kiln
sections, and finally fitting new lining in the deformed part of
the kiln shell.
Kiln Shell Ovality Based On Migration
Measuring of Live Ring Migration
Measuring of Live Ring Migration
Kiln shell in live-ring
Ideal and real conditions
Elastic Deformation

Wor = dov - dol

Clearance / Live Ring Migration Live ring migration
Constriction of kiln shell
Measurement Of Live-Ring Migration
Measuring of Live Ring Migration

v =  (DL - Do)
2s = (DL - Do)
v =  x 2s

ΔD = v/1.5 to 2
Kiln revolution curves
 Interpreting The Migration
Normally, an increase in the live-ring migration is caused by:
* Wear on the supporting blocks where such do not exist, on
the kiln shell itself, caused by ineffective lubrication between live-
ring and live-ring supporting blocks, which can, e.g. be the case
when the environment at the live-ring is very dirty. To ensure
effective lubrication, it is necessary to use:
•correct Lubricant,
•correct Lubricating method,
•correct Lubricating frequency,
As will be described later in this section.

* Constriction as described previously in this section

 Live-Rings - Reduction Of Migration

If the kiln has a constriction, it may be impossible

to do a proper lining work resulting in an unacceptably
short life of the lining. In such a situation, the kiln
section in question should be replaced.

In case the live-ring migration increases due to

wear to such an extent that the ovality and bending
stress values approach an unacceptable level, corrective
action should be taken to reduce the ovality in order to
avoid a real breakdown. The choice of method depends
on the type of kiln shell: with or without live-ring
supporting blocks.
 Kiln Shell With Live-Ring Supporting Blocks

t = mean thickness V = live-ring migration

t = (v - 10)/2p
("t" and "v" in mm)

Before deciding on the thickness of the shims to be

inserted under the live-ring supporting blocks, the
following measuring program should be earned out:

* Live-ring migration
* Temperature on the surface of the live-ring
* Temperature on the kiln shell on the inlet side and on
the outlet side of the live-ring
Kiln Shell Without Live Ring Supporting Blocks
 Live-Ring – Lubrication

1) The contact faces between live-ring and supporting

blocks or lain shell
2) The contact faces between live-ring and side guides

The following lubricants are suitable for the purpose:

 Kiln Shell Ovality Based On Radial Deformation

Difference between horizontal and vertical diameter

Ovality  = dh - d v

Twice the difference between horizontal and vertical semi-axes

Ovality  = 2 (a - b)
0
In order to compare the ovality behavior of kilns of different
sizes , the ovality is expressed as an percentage of the kiln
nominal diameter (di).

Absolute ovality a = 2 (a - b) {mm}

Relative ovality r = {%}

 Ovality
Definition
The recommended ovality
range is shown as a
function of the kiln
diameter, found by
experience.
For a kiln with a diameter
of 5.2 m the diameter
difference
(dh - dv = ovality) should
not exceed 26 mm in order
to keep the relative ovality
below 0.5 %.
Principle of the measurement
 Principle
of
the
measurement
Measurement
procedure

Calculation of the
shell ovality
based on
“Shelltest”
records
 Relationship Ovality- Deformation

dh - dv = d  h

2
4  d 
Ovality   2 (a - b) =     [mm]
3 L
 Interpretation of
the Shelltest
Record

(d = dh - dv) and the

maximum deformation
(hmax = ) as
indicated on the
“Shelltest” record, since
d is not identical with
h (Fig. 21). h is the
shell deformation
based on a circular
segment length L = 1
m.